Artificial fiber board



April 27, 1943. H. E. WALTER ARTIFICIAL FIBER BOARD Filed Feb. 5, 1940 2Sheets-Sheet 1 2 SheetsSheet 2 H, E. WAYLTER ARTIFICIAL FIBER BOARDFiled Feb. :5, 1940 April 27, 1943.

Patented Apr. 27, 1943 2,317,504- ARTIFICIAL FIBER BOARD Henry E.Walter, Cloquet, Minn, ,assignor to Wood Conversion Company, OIoquet,MimL, a

corporation of Delaware Application February 3, 1940, Serial No. 317,0637 Claims. (CI. 41-24) Th present invention relates generally to Imarking temporarily plastic material in the proc-' ess of manufacture toproduce permanent markings. It has particular reference to themanuiacture of fibrous felts, such as thick paper or artificial board togive decorative surfaces.

The use of artificial board for walls in certain places is limited bythe fact that the common boards giving a desirable fibrous texture aretoo soft, at the surface to resist scarring and sending, and are notsufficiently resistant to water to avoid spotting and to permit washing.Thus, for example, in the position of Wainscot, boards of desirabledecorative appearance lack qualities for such usage. The presentinvention aims also to produce wall boards which are suitable for use asdecorativev Wainscot.

One object of the present invention is to produce intaglio impressionsnot of a definite pattern, but of a characteristic appearance innonrepetitive form; and to provide a means for that end.

Another object of the invention is to produce such boards with a hardsurface which is resistant to spotting with water, to marring andscuffing, and which may be washed. 1

A particular object is to produce a decorative Wainscot panel of thefibrous wallboard type.

The invention will be described with particular reference to artificialboard made from an aqueous slurry' of fibers, but it is to beunderstood, and it will be pointed out, that it has otherapplications;and that the device of the invention, and the manner of using it mayvary considerably. Havirlg reference to the accompany drawings, theinvention will he illustrated and explained as it is applied in markingartificial board In the drawings:

Fig. 1 is a reproduction of a photographed pic In order to attain anon-repetitive pattern the impression means is multiple and each elementis in part mobile and free to assume different positions. Each elementis also in part constrained and fixed in part with respect to a carrierof the multiple elements, so that there is pro duced by the constraint,a generalidentity, or individual character in the design, and a pleasingnon-repetitive variation in the design produced by the mobile parts. I

This is readily accomplished where a design of lines is desired, byhaving one or more carrier elements to which a multiplicity of strandsor cords is attached at points spaced along the strands or cords, eachstrand or cord being loose relative to the carrier between each twoadjacent spaced points of attachment to the carrier, the looseness beingdue both to non-attachment to the carrier and to the cord or strandhaving a length greater than the distance measured in the carrierbetween adjacent points of attachment. Therefore, when the carrier istaut, the strands are not taut, and they may assume any free positionbetween the points of attachment.

The carrier is one or more elements adapted to be pulled taut, in onedirection. The carrier is preferably a sheet backing. It may be a felt,or canvas, or rigid or flexible net, or merely be a plurality ofparallel cords without lateral connections between them in the area usedfor impressions. The latter arrangement, and a coarse netting, cantherefore be used in a taut position with varying widths coverable bythe same backing, giving a finer. or coarser pattern in the lateraldirection.

The strands or cords may be of fiber; such as rope, yarn or cord, orflexible wire or even rubher, and the latter may be smooth or marked, asdesired. One strand, for example, may be attached to the backing atevenly spaced intervals in a straight line, running generally in thedirection of the taut backing, or definitely angular to it, or in someirregular line. Other cords may have an exactly similar attachment, andall points of attachment be arranged in parallel lines across the tautlength. Some may be staggered with respect to others. There may bestrands across the taut length. These may be attached to the backing, oreven be a part of the backing, as

where a coarse net is'used, and not stretched laterally when it ispulled taut lengthwise.

In other words, the character of the backing, or the manner in which itis applied as a carrier, coupled with the pattern of the fixed points ofattachment, is the means to;provide the desired character or generalidentity to a design. The manner in which the cords or strands are freeto assume difierent positions, is the cause of variation in the pattern,and the particular cause of a non-repetitive pattern.

In order to avoid showing the many possible variations of the pattern,one illustrative form is selected, which gives a pleasing effect. InFig. 2.there is shown a carrier which is a coarse net having a warp ofheavy cords l adapted to be pulled taut to apply the carrier. Lighterweight transverse cords II are shown and at the intersections, any typeof connection may be applied. When the net is expanded laterally to thefull permissible width the transverse cords ll will be taut, but for thepurpose of illustration the net is shown slightly contracted laterallywit a taut warp, whereby the transverse cords tween the warp cords areirregularly arranged, and will make a variable design where they maypenetrate the plastic material.

In Fig. 3 the diagrammatic block l2 indicates the edge of a carrier, andthe single cord II thereon is representative of the strands which makethe design. Cord II is shown with three spaced attachments II, I! andii, of which I! and II are points, while I4 is a length of cord l3secured to carrier l2. On any carrier, the places of attachment, like Itand It, may be repetitive or non-repetitive in design. The repetitivedesign for attachment may be such as to give always an individualcharacteristic to the resulting effect, with uncontrollable variationsfrom the loose parts. In Fig. 2, the strands or cords are designated l1,and the places of attachment are points iii, in a row across orotherwise disposed on the backing. Each strand I1 is shown with itsseries of spaced attachments alined, not in a straight line, but instaggered relation, with looseness of strand between adjacent points inthe taut carrier. Thus the strands may fall into wavy lines generally,but not mathematically or regularly, or repeatedly. From the foregoingit is obvious how the arrangement may be varied.

Where the carrier or backing is a flexible sheet relatively closed, likecanvas, the strands are located on the impressing surface thereof. Butwhere the carrier is more open, like a net, the strands may be on eitherside thereof, or both sides. Where the strands cross the net on thenon-impressing side, the cords of the net may be utilized as part of theimpression means. Likewise, the cords of the net may function where theyare exposed on the impression side, between strands l'l.

Fig. 4 represents one way in which such an impression fabric may be usedin a continuous machine for making artificial board,

Numeral indicates a Fourdrinier or forming wire or screen on which thewet fiber mat 2| is formed and on which it is yet quite plastic throughthe retention of water. This screen runs along over supporting rolls 22,then through a set of heavier press rolls 2! and 24, lighter press rolls26 and 21, heavy squeeze rolls 2!,and 28, and a second set of squeezerolls 20 and II. The wire returns over the lower roll 20, and the moistor damp fiber layer 32 is quite self-supporting, and ready to be dried.As the plastic mat 2| enters these rolls it receives on its top astretch of an endless impression carrier 32 according to this invention,and an endless thick felt 24 which takes up water squeezed out. Rolls3|, 3! and 20 carry the felt 24. Rolls ll, 25, 21, it, 3!, and II carrythe impression blanket. Roll 30 depresses the blanket into washing tank42, so that it may be cleaned of adherent fiber to assure impressionsnow set in the mat. Then the board goes to drier N.

In the manufacture of board as described in the machine of Fig. 4, it isobvious that the felt 34 may itself provide the carrier generallydescribed without departing from the invention. A separate carrier ispreferred for many reasons. It is also to be understood that in manyboardmaking machines there is used a top-wire as well as the lowerforming-wire. The top-wire also may be used as the carrier for thepresent invention.

It is further to be understood that I have described the invention interms of carrier" and loose elements in order to explain clearly thefunction as a carrier, and belong to set I] at is used again. At theroll II the loose impression material is removed from the permanentanother part of the structure to function as a mobile element. It istherefore to be understood that the invention in its broadest aspectprovides a marking structure which as a whole is capable of being pulledin a taut relation to fix the position of the flxations of the mobileelements, so as to present mobile elements for self-positioning. Thepattern designed, and the questions of construction with ease andeconomy determine the exact construction of the device.

It is of course to be understood that a single length (not an endlessbelt) of impression blanket, may be used where a non-continuous processis used. For example, it may be used in the press shown in U. S. ZiskaPatent No. 1,690,152, which is used in an intermittent operation inmaking artificial board, serving at the same place as the press rollsabove described.

In the preferred operation of the process, the wet board marked as abovedescribed, is dried by the use of a drier whichhas hot flattening orpressing means. These operate to reduce the higher spots to the samelevel, giving a uniform caliper to the board. The depth of thedepressions in the surface from the caliper surface has a great eifectupon the appearance of the board for ornamental effect. When thedepressions are of depth of about 0.02 inch, the depression becomescapable of indicating high lights and shadows on proper lighting, suchas any wall is normally subjected to. This is practically the minimumdepth, but of course, the high lights and shadows depend upon a ratherabrupt drop in the surface from the caliper level or any lower generallevel, adjacent the depression. It isthe form of the depression and thesize and depth as well, which are factors to give this eflect.

For a board involving the present invention the depth of the depressionsmay vary from .005 to .04, with a predominant number of them from .02 to.04 inch deep to give high lights. The width of the depressions may varyup to twice the depth to give the high lights and shadows, andpreferably the width is not greater than the depth.

The board with the design illustrated is particularly useful forWainscot, with the lines of the pattern running vertically. In such useit is subjected to considerable scufling. Therefore, it is desirable toincrease its utility by v pressed mat before drying.

hardening the surface. This may be done by a coat of paint, varnish orother substance applied to the dry board. It may also be done byapplications of suitable coating to the wet im- Such coatings maycontain pigments to cover the fibers, as described in the copendingapplications which may later be referred to. 'Theseinclude aqueous basecoats of pigments and binder, which binder may be protein, resinous,starch, or other s able substance. However, the board may be coated witha non-pigment material effective to harden the surface of the board.

For example, a drying oil may be applied in the form of an oil emulsion,under conditions to induce drying or hardening of the surface while theprocessing of the board is being completed. By incorporating a dryingoil and a drier in an aqueous emulsion, the emulsion may be spread ontoa wet mat which ultimately provides the board with the oil limited toand concentrated in the surface layer of the board. Thus, the wet matbefore or after the making of design impressions, is treated with suchan emulsion, so thatv in hot pressing the board the oil is hardenedwhile the fibers are still wet in the coreof the board, thusconcentrating the cu. ft. It may be applied up to'30 pounds per 1000 sq.ft. and in practice from 11 to 22 pounds of China-wood oil is used forsuch wood fiber boards. i

A suitable emulsion is as follows:

Per cent by weight Water 69.4

China-wood nil 27.8 Japan drier 2 Sodium carbonate .4

Dyestuifs (for color) .4

The sodium carbonate and water at 90 to 110 F. are used as a liquidvehicle to which the mixed and oil are added with emulsifying agitation.Not only'the vegetable drying oils such as Chinawood oil, soya bean oil,linseed oil, perilla oil, 'oiticica oil and others may be used, but alsothe synthetic drying oils produced from non-drying vegetable oils andfrom petroleum and other bydrocarbon bases; By the term drying oil asused herein is meant any oil not miscible with water which by oxidation,with or without a drier, will form a solid substance, as in paint.

The oil emulsion may be used before or after the impressing of a designinto the board, so long as it is applied while the board is wet. The

Such a a finished board of which the. natural surface felt is cut tomake a design.

The present application is a continuation in part of myapplicationSerial No. 220,355, filed July 20, 1938. The subject matter relating tothe use of drying oil is describedand claimed in my 4 application SerialNo. 317,105, filed February 3,

It is of course to be-understood that th same method and impressionmaterial may be used in cement, plasterboard, gypsum board, and othertemporarily plastic body-materials having a decorative surface. Theseare impressed while plas- V tic, partially set to hold the impressions,and then completely setafter removal of the impressionmaking means.

The invention obviously is not limited to sub facing fiber boards, butmay be used on any plastic material. Therefore the invention is broadlydefined in the appended claims.

I claim:

1. An artificial decorative 'board for use on walls and the like inposition subject to marring or scufiing having a surface of feltedfibers with intaglio markings therein, the felted connection of thefibers of said surface being unbroken by the depressions of themarkings, said continuous felt of surface fibers embodying a dried oil,the main body of the board beneath said surface'be ing softer and beingfree from dried oil,,the depressions being in the nature of grooves from.005 to .04 inch deep, the width of -a groove be ing not mor than twicethe depth, the majorportion of the high spots between the said groovesbeing substantially in the same plane, whereby a fiat surface isprovided with decorative high lights and shadows upon illumination.

2. An artificial decorative board for use on walls and the like inposition subject to marring or scuffing having a surface of feltedfibers with intaglio markings therein, the felted connection of thefibers of said surface being unbroken by the depressions of themarkings, the depressions extending in the same general direction, saidcontinuous felt surface fibers embodying a hardening agent, the mainbody of the board beneath said surface being softer than said surfacelayer andbeing free from said hardening agent, the depressions being inthe nature of grooves from .005 to .04 inch deep, the width of a groovebeing not more than twice .the depth, the major portion of the highspots between the said grooves being substantially in the same plane,whereby a fiat surface is provided with decorative high lights andshadows upon illumination. 3. An artificial decorative board for. use onwalls and the like in Position subject to marring oil-particles of theemulsion are thus filtered out trationof oil. making a small amount veryefor scufiing having a surface of felted fibers with intagliomarkingstherein, the felted connection of the fibers of said surfacebeing unbroken by the degressions of th markings, the depressionsextending in the same general direction, said continuous felt of surfacefibers embodying a dried oil, the main body of the board beneath saidsurface being softer and being free fromdried 11, the depressions beingin the nature of a groove being not more than twice the. depth,

th major portion of the'high spots between the said grooves beingsubstantially in the same plane,

whereby a flat surface is provided with decorative high lights andshadows upon illumination.

' 4. An artificial decorative board for use on walls and the like inposition subiect to marring and scufllng comprising a body of feltedfibers having a surface with intaglio markings therein, the feltedconnection a: the fibers of said surface being unbroken by thedepressions of the markings, and dried-oil in the surface layer as ahardening agent, the main body of the board beneath said surface-beingsofter than said surface layer and being free'from said dried oil.

5. An artificial decorative board for use on.

- having a surface with inta glio markings therein,

' the felted connection of the fibers of said surface being unbroken bythe depressions of the markings, and dried oil in the surface layer as ahard- CERTIFICATE 'OF comcnon. Patent No, 2, 17, ou. April 27, 1915.

HENBY E. WALTER.

Ibis hereby certified that error appears in the printedgpecifigatip n ofthe a gye numbered pater rb requiring correction as follows: Page 3-first -co1umn, 1ine 51,:tor fwshing" r --wash1ngline 51+,after "mixed"in--' sert --dr1er--; and second column, line 70, claim 3, for "deg1-essions" read L the Patent Office.

-depr ss and that the said Letters Pate'nt should be read with an;correction thereinthat the same may confdrm to the record'ofthe case' inSigned and. sealed this 8th'daj of June,.A. D. 191), 4

Hnry Vgn Ar s da1e 5 (Seal) I Acting Commissioner offat en ta.

